Process to prepare a premium formulated fried egg

ABSTRACT

The present invention relates to the formulation and process for preparation of a fried egg product which may be frozen for future heating within a microwave or other oven for consumption by an individual. Various ingredients are added and mixed to each of the liquid egg white and liquid yolk portions. The liquid egg white portion is preheated and then deposited within a mold for slow cooking under controlled temperature and humidity conditions. The liquid yolk portion is preheated and then is added to the mold for placement on the egg white portion. Following a short period of cooking the mold containing the formulated fried eggs is transported to a freezer unit for freezing, packaging, and storage. At a future time the frozen formulated fried egg product may be retrieved for thawing and cooking for consumption by an individual.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Ser. No. 10/161,046,filed May 31, 2002, now pending, and claims priority to U.S. ProvisionalPatent Application No. 60/342,405, filed Dec. 21, 2001, the contents ofboth of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention is directed to a formulation for a fried eggproduct and process to prepare a premium formulated fried egg forconsumption by an individual. It is anticipated that the formulatedfried egg product will be refrigerated and/or frozen for future heatingwithin a microwave, convection oven or griddle for consumption as astand alone food item or as a portion of a composite food article. Theformulated fried egg has a texture and other sensory perceptions similarto a naturally fried egg.

In the past, formulated fried eggs have been formed by the filling of amold with a liquid egg mixture and then cooking the liquid egg mixturewithin the mold. Many problems have arisen through the implementation ofthis processing methodology. Formulated fried eggs produced according tothe above identified methods unfortunately have the appearance and tasteof commercial processing. Frequently these food articles after cookingare extremely dense having poor viscosity. Formulated fried eggs cookedwithin a mold generally exhibit undesirable sensory perceptions relatedto the appearance, taste and texture as compared to a freshly fried egg.A need therefore exists to eliminate the dense commercial processingappearance and taste associated with a formulated fried egg product ascooked within a mold.

In the past procedures have generally not been implemented to rigorouslycontrol the processing and cooking parameters utilized to yield aformulated fried egg. A need exists to develop a formulated fried eggwhich is more appealing in appearance and taste and which is susceptibleto freezing and reheating within a conventional or microwave heatingprior to consumption by an individual.

In the past the freezing and/or extended refrigeration of a formulatedfried egg has lead to a loss of a cohesive texture and the degradationof other sensory perceptions such as mouth feel, taste, elasticity,and/or the food product not being tender or appealing to an individual.

Another common problem encountered during delayed consumption, extendedrefrigeration and/or freezing of a formulated fried egg is that the foodproduct exhibits syneresis, or the loss of water when frozen andreheated, or when stored for an extended period of time.

In the past, temperature variations during the cooking procedure for theformulated fried eggs have caused a degradation in the viscosity, lossof elasticity, and have resulted is a non-smooth, non-cohesive texture.In addition, temperature variations have caused the formulated fried eggto be not tender and fail to easily fracture and break during attemptsto rupture the egg yolk portion of the formulated fried egg. The cookingof the formulated fried egg at an elevated temperature, to minimize theduration of the cooking time, frequently results in the burning anddegradation of the texture of the formulated fried egg. Also, duringrapid cooking the formulated fried eggs easily dehydrate and form acrust which is unappealing to an individual.

The rate of cooking of the formulated fried eggs and the temperature ofthe oven, or other cooking vessel, also frequently cause the formationof an excessive volume of air bubbles, which in turn, interrupt thestructure of the formulated fried egg destroying the smooth, cohesivetexture. The loss of a smooth cohesive texture causes an undesirablemouth feel when consumed by an individual. The existence of undesirableand/or excessive air bubbles may also occur when the pH of theformulated fried eggs is at an improper level, preventing the egg whitesfrom retaining carbon dioxide as carbonic acid. The reduction in theamount of carbon dioxide and/or carbonic acid causes the mixing and/orshearing of the egg whites during processing due to undesirable gasentrapment.

In the past the cooking of formulated fried eggs has frequently causedan iron-sulfide greening reaction resulting in undesirable colorationand a degradation in the taste for the egg product.

It is also desirable to provide a formulated fried egg which is naturalin appearance. In the past formulated fried eggs have included asymmetrically located egg yolk portion as centrally positioned within asubstantially round egg white portion. These types of formulated friedeggs do not appear to be natural. Natural fried eggs experience randomyolk positioning and non-symmetrical egg white portions.

The known formulated fried egg processing techniques frequently causefreezing and/or thawing damage to frozen eggs and fail to retain the eggyolk portions in a semi-liquid state after freezing and subsequentthawing and heating. As a result the egg yolk portions of the knownformulated fried eggs have not readily fractured, have not provided asemi-liquid state, nor have provided a desired elastic texture.

BRIEF DESCRIPTION OF THE INVENTION

The present invention relates to the formulation and process forpreparation of a fried egg product which may be refrigerated and/orfrozen for future heating within a microwave or other oven forconsumption by an individual. The process involves the initial step ofacquisition of liquid eggs which may be separated into liquid egg whiteand liquid egg yolk portions. Various ingredients are added and mixed toeach of the liquid egg white and liquid yolk portions. The liquid eggwhite portion is preheated and then deposited within a mold for slowcooking under controlled temperature and humidity conditions. The liquidyolk portion is preheated and then is added to the mold for placement onthe egg white portion. Following a short period of cooking, the moldcontaining the cooked egg white and egg yolk are cooled and thentransported to a freezer unit for freezing. The frozen formulated friedegg is then separated from the mold for packaging, and storage. At afuture time the frozen formulated fried egg product may be retrieved forthawing and cooking for consumption by an individual. The formulatedfried egg product made according to the parameters described hereinyields a enhanced fried egg product having sensory perceptions and theappearance of a naturally fried egg.

The liquid egg white portions, the liquid yolk portions and additionalingredients are individually mixed under controlled conditions to avoidover mixing and/or over gassing of the liquid egg portions which wouldadversely affect the quality of the end product. Alternatively, theformulated fried egg product following cooling and freezing may beseparated from the mold for storage within a freezer or refrigerated forfuture reheating and consumption by an individual.

A principle advantage of the present invention is to create a formulatedfried egg product having improved texture.

Another principle advantage of the present invention is to create aformulated fried egg product which has a homemade look for the reheatedfried eggs.

Still another principle advantage of the present invention is to createa formulated fried egg product which may be formed through the use ofcommercially available equipment.

Still another principle advantage of the present invention is to createa formulated fried egg product which has a light and airy textureresembling naturally fried eggs.

Still another principle advantage of the present invention is to createa formulated fried egg product which has a more appetizing appearance.

Still another principle advantage of the present invention is to providean improved formulated fried egg product formed from relatively simpleand inexpensive ingredients and processing equipment which fulfills theintended purpose of enhancing the appeal and appearance of a formulatedfried egg product without fear of damage to the food article and/or foodprocessing equipment and/or illness to individuals.

Still another principle advantage of the present invention is theaddition of modified food starch to a formulated fried egg product toenhance the quality of the food article.

Still another principle advantage of the present invention is theaddition of gums to improve the appeal of the food article.

Still another principle advantage of the present invention the use ofFDA approved ingredients for formulation of a fried egg product.

Still another advantage of the present invention is the provision of theefficient control of mixing and cooking parameters to formulate adesired quality of formulated fried egg product.

Still another advantage of the principle invention is the provision of aformulated fried egg product which may be held as frozen, refrigerated,and/or hot for extended periods of time without loss of productintegrity to minimize waste.

Still another principle advantage of the present invention is theprovision of a formulated fried egg product which has been processedover specific durations of time.

Still another advantage of the principle invention is the provision of asuperior formulated fried egg product which includes integritycharacteristics not found in other food articles within the same productclassification.

Still another advantage of the principle invention is the provision of aformulated fried egg product having enhanced product consistency whichis not found in other food articles within the same productclassification.

Still another advantage of the principle invention is the provision of aformulated fried egg product which remains intact followingrefrigeration and/or freezing and subsequent reheating for consumptionby an individual.

Still another principle advantage of the present invention is theprovision of a formulated fried egg product having improved texture andflavor as related to other food articles within the same productclassification.

Still another principle advantage of the present invention is theprovision of a formulated fried egg product which minimizes sogginess ofthe egg product during processing, cooling, refrigeration, and/orfreezing and subsequent storage for further reheating prior toconsumption by an individual.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 shows a mold utilized to cook the formulated fried egg;

FIG. 2 shows is a block diagram showing the processing steps during theformation of the fried egg product.

DETAILED DESCRIPTION OF THE INVENTION

In general, the disclosed invention relates to a formulated fried eggproduct, and a process to prepare the formulated fried egg product. Theformulated fried egg product is generally formed of an egg white portionand an egg yolk portion.

The formulated fried egg product following cooking is preferably frozen,thawed, and heated prior to consumption by an individual and/or prior toincorporation into a composite food product.

The disclosed formulation for the fried egg product, and process toprepare the formulated fried egg product, originates with liquid eggwhites and liquid egg yolks which, when cooked, and combined with otheringredients, may be frozen and/or refrigerated for reheating withinmicrowave ovens, convection ovens, griddles or any other type of heatingdevice without limitation, for consumption as an individual orcombination component for a consumable food product. The formulatedfried egg article may include a wide range of egg product and ingredientformulations, which when mixed, frozen and/or refrigerated, followed byreheating result in a visually and sensory appealing formulated friedegg.

The process for forming the fried egg product for future reheatingwithin a microwave or other heating oven or griddle is distinctlydifferent in certain physical characteristics as related to standardprocessing techniques.

Ordinarily one would not expect the control of ingredients, theregulation of temperature, the control of cooking conditions, and themanagement of mixing parameters during food processing to yield anenhanced formulated fried egg product. The failure to control ingredientproportions, regulate the temperature of the ingredients, the conditionsof cooking, and/or the management of mixing parameters significantlydegrades the integrity of sensory and taste perceptions for the friedegg product. Control of ingredient proportions, regulation of thetemperature for the ingredients, limitations upon cooking conditions,and management of mixing parameters provides enhanced consistency andintegrity for the formulated fried egg product and reduces sogginess,enhancing the likelihood that the formulated fried egg will remainintact through processing, freezing or refrigeration, and subsequentreheating prior to consumption by an individual. The control ofingredient proportions, regulation of ingredient temperature, limitationof cooking conditions, and management of mixing parameters alsomaximizes the retention of a cohesive texture and sensory perceptionsassociated with a composite formulated fried egg product.

The formulations and food processing techniques described hereinminimize undesirable effects of the fried egg being rubbery, orexhibiting syneresis or loss of water when frozen, reheated, or whenstored for an extended duration of time. The formulations and foodprocess techniques described herein further minimize waste of theconsumable formulated fried egg.

The present methodology for formulation of the fried egg product occursthrough the acquisition of farm packaged, ungraded, washed, fresh eggs,where the egg whites have been separated from the egg yolks by hand ormechanical egg shelling techniques. Care should be utilized to avoidovergassing of the egg white component of the formulated fried eggduring exposure to mechanical egg shelling and separation techniques.The liquid egg white and/or liquid egg yolk portions of the formulatedfried egg may be obtained from shell eggs and/or pasteurized shell eggs.It is desirable for the liquid egg yolk portion of the formulated friedegg to be semi-solid following cooking and reheating after being frozen.Dried egg white powder and/or egg yolk powder may be added to the liquidegg yolk portion to improve the density, texture, and mouth feel for theegg yolk portion of the formulated fried egg.

The liquid egg whites as separated from the liquid egg yolks form thestarting materials for the formulated fried egg product. In general, theliquid egg whites may be uncooked or pasteurized for use as the startingmaterial.

First, the starting liquid egg whites are maintained in a suitablecontainer and may be refrigerated for later mixing with supplements toprovide a superior taste, appearance and texture for the formulatedfried egg. Preferably, the liquid egg whites are not stored asrefrigerated but are immediately used for processing into the formulatedfried egg.

The formulated fried egg product preferably has the physical andchemical characteristics of a natural fried egg and is sensorilyacceptable as a formulated fried egg product in substitution for astandard natural fried egg.

In general, the process for formulation of the fried egg includes:obtaining a desired amount or volume of unshelled liquid egg yolks, andliquid egg whites and placing the unshelled liquid eggs into separatemixing tanks or vessels. In a third and forth separate tank, “dryingredients” including, but not necessarily limited to, oils; gums andmodified food starches; non-fat dry milk; salt; water and citric acidmay be placed. The “dry ingredients” are then preferably separatelymixed. The mixed “dry ingredients” may then be introduced into therespective vessel containing liquid egg whites and/or liquid egg yolkswhereupon mixing should occur. Alternatively, the applicable “dryingredients” may be directly mixed within the individual vesselscontaining the liquid egg whites and/or the liquid egg yolks.

Mixing may occur through the use of an Admix High Shear Mixer for adesired period of time which may be five minutes at a speed of 3450rotations per minute resulting in a homogeneous liquid egg white and/oregg yolk product. Mixing may result in the formation of a foam which ispreferably removed from the liquid egg white and/or liquid egg yolkmixture.

Alternatively, the ingredients for the liquid egg whites and liquid eggyolks may be mixed for approximately 5 to 10 minutes and then the mixedliquid egg whites and liquid egg yolks may be pumped through commercialprocessing equipment for deposit into a mold for cooking in a commercialconvection oven. Alternatively, the liquid egg whites and/or liquid eggyolks may be mixed through constant stirring for a desired period oftime whereupon the mixed liquid egg whites and liquid egg yolks may bepumped into the depositor for further processing. Alternatively, themixed liquid egg whites and/or liquid egg yolks may be homogenizedthrough commercially available homogenizing equipment. It is alsogenerally desirable to avoid excessive mixing or agitation of the liquidegg whites and/or liquid egg yolks which may result from the use ofpowerful mixing equipment. Excessive mixing causes aeration within theliquid egg product resulting in the formation of air bubbles duringcooking of the formulated fried egg. Excessive agitation may furthercause the degradation of the egg whites and/or egg yolks adverselyaffecting the quality of the formulated fried egg product.

The ingredients of the liquid egg white and/or liquid egg yolk may bemixed within a Krämer & Grebe multi-mix mixer. Alternatively, the liquidegg whites and/or liquid egg yolks may be mixed within a Hobart blender.The mixed liquid egg whites may be placed within individual molds by aKoppens dispensing machine which may regulate the desired volume of themixed liquid egg whites within each individual mold.

The mixed liquid egg whites may then be pumped for preheating within aheat exchanger. The mixed liquid egg yolks may also be pumped forpreheating within a second heat exchanger. The preheated liquid eggwhite product may then be pumped into a depositor. The preheated liquidegg yolk product may then be pumped into a second depositor. Finally,the preheated liquid egg whites are deposited in a mold for cooking.Following an initial period of cooking the egg yolk portion is depositedupon the partially cooked egg white portion within the mold. Furthercooking of the egg white and egg yolk portions normally follows bypassing of the molds containing the preheated liquid egg whites andyolks through a convection oven. The cooked fried eggs are then cooled,frozen, and removed from the molds for appropriate storage and/or forreheating and inclusion within a food product such as breakfastsandwich.

Alternatively, the process for formulation of a fried egg product mayinclude obtaining a desired amount or volume of unshelled liquid eggwhites, and egg yolks. Placing the unshelled liquid egg whites and yolksinto separate mixing tanks for mixing with initial ingredients such asoils, gums, modified food starches, salt, and water. Next the liquid eggwhites and liquid yolks may be pumped to a heat exchanger forpreheating. Next, the mixed liquid egg whites and yolks may be pumped toa respective depositor, whereupon a desired amount of preheated liquidegg whites are deposited within molds. The mold then passes a seconddepositor containing the liquid egg yolks for depositing of the liquidegg yolk portion into the mold on top of the uncooked liquid egg whiteportion. The molds containing the liquid egg whites and yolks are thenpassed into an oven for cooking. The cooked formulated fried eggs arethen cooled, frozen, and removed from the molds for appropriate storageand/or for inclusion within a food product.

Initial homogenizing of the liquid egg whites and/or yolks may occurprovided that the homogenizing methods utilized do not significantlydelay the continued cooking of the mixed liquid egg whites and/or liquidegg yolks. Preferably, the mixed liquid egg whites and liquid egg yolksare cooked within a few hours of mixing and more preferably cookingoccurs immediately following the mixing of the liquid egg whites andliquid egg yolks.

Citric acid and/or citric acid in combination with xanthan gum may beadded to the liquid egg yolk. The citric acid slows the iron sulfidegenerating reaction during cooking and improves the appearance of theegg yolk while simultaneously increasing the viscosity of the egg yolkat lower cooking temperatures.

It is desirable for the egg white portion following cooking to beelastic, smooth, have a cohesive texture, be tender and fractureproviding the appearance of a natural egg white portion of a fried egg.To achieve egg white consistency, minimization of air bubbles isrequired which reduces cupping, graininess, and freezer/thawdegradation. In order to assist in the improvement of the consistencyand texture of the egg white portion, polar gel modified food starchand/or purity modified food starch may be added. Polar gel starch inmost applications provides slightly better texture and consistency forthe cooked egg white portion of the formulated fried egg. The use ofpolar gel starch at a level of approximately 1.5% also provides adequatefreezer/thaw protection for the formulated fried egg. In addition, thetexture and/or appearance of the egg white portion or yolk portions maybe influenced by the type of gum which is added to the formulated friedegg. To improve texture and/or appearance, guar and/or xanthan gumprovide acceptable results upon cooking of the formulated fried egg. Thetexture and/or appearance of the formulated fried egg following cookingis improved through the addition of a combination of modified foodstarch and gum. The use of excessive modified food starch should beavoided to minimize perceived rubberiness and undesirable mouth feel forthe formulated fried egg. The use of xanthan gum also improves the mouthfeel characteristics for the formulated fried egg following cooking.

In order to minimize undesirable bubbling particularly within the eggwhite portion a procedure may be implemented to degas and to remove airbubbles from the liquid egg whites. A vacuum treatment may be introducedfor a period of approximately two hours in order to attempt to draw airbubbles to the surface of the liquid egg whites. Air bubbles may floatto the surface of the liquid egg whites following depressurizing of thecontainer holding the liquid egg whites. Initially, commercial processedbroken out egg whites are more susceptible or disposed to bubbleformation than hand broken eggs. Separation of the egg whites from thehand broken eggs generally yields intact egg magma minimizingundesirable air bubble formation.

The pH of the liquid egg white portion is normally between 8.2 to 8.5.An increase in the pH of the liquid egg white portion to a level between8.8 and 9.1 decreases the volume of air bubbles and reduces the cuppingof the egg white portion during cooking. Further, an increase of the pHto approximately 9 for the liquid egg white portion results in greaterfreezer/thaw protection reducing damage to the formulated fried eggfollowing cooking and subsequent freezing.

The use of 1.0 ml. of 1.0 normal NaOH (40 g/960 ml. water) atapproximately 1.0 ML. NaOH solution to 100 ml. of liquid egg whitesincreases the pH from approximately 8.4 to 8.8. The greatest effect ofbubble and cupping reduction for the liquid egg whites occurs when thepH is approximately 9.0 accompanied by a low percentage of modified foodstarch and xanthan gum.

In general, the ingredients for the egg white portion and the egg yolkportion are not required to be combined in any preferred order formixing. The ingredients of the egg white portion and the egg yolkportion are preferably mixed cold at a temperature between 32° F. and40° F., 0° C. and 4.44° C. and more preferably less than 40° F., 4.44°C. Water may be added to the “dry ingredients” to facilitate mixing. The“dry ingredients” and water may then be mixed into the respective liquidegg whites and/or liquid egg yolks to formulate the individual corecomponents for the formulated fried egg product. The mixing time for therespective egg whites and/or egg yolk portions is reduced to a minimumand generally is no longer than necessary to insure adequate mixing. Themixing may occur through the use of a high shear mixer as iscommercially available.

Following the completion of mixing of the liquid egg whites and/orliquid egg yolks, a preheating step may occur prior to the cooking ofthe fried egg product. In operation, the preheating phase is generallycontinuous for the enhanced mixed liquid egg whites and liquid eggyolks. Preheating occurs as the liquid egg white mixture and liquid eggyolk mixture is pumped through a respective set of equipment forintroduction to a tube to tube heat exchanger for each mixture. Thetemperature of the enhanced liquid egg white mixture and liquid egg yolkmixture prior to the respective tube to tube heat exchanger isapproximately 40° F., 4.44° C.

The temperature of the enhanced mixture of liquid egg whites and liquidegg yolks exiting the respective tube to tube heat exchanger and/or arespective scraped surface heat exchanger following completion ofpreheating is approximately 135° F., 57.22° C. The preheating phaseelevates the temperature of the enhanced liquid egg white mixture andliquid egg yolk mixture prior to the introduction of the liquid eggwhite mixture and/or liquid egg yolk mixture into a respectivedepositor. The preheating of the mixed liquid egg whites and mixedliquid egg yolks may occur within individual tube to tube heatexchangers identified as a Feldmeier systems.

In addition, the preheating procedure may continue through the use ofscraped surface heat exchangers which may be identified as ConthermSwept Surface Heat Exchangers. It should also be noted that thepreheating may be eliminated and/or significantly reduced so long ascooking times and temperatures are correspondingly adjusted for cookingof the enhanced formulated fried egg at a sufficiently low temperatureand for a sufficiently short duration of time to avoid burning,sticking, and/or other undesirable complications associated with thecooking process. Undesirable complications include, but are notnecessarily limited to, excessive bubbling where the starting liquid eggwhites and/or liquid egg yolks have not been previously preheated. Theformation of an undesirable skin for the fried egg and the undesirablehardening of the egg yolk portion, undesirable skin formation usuallyoccurs when the formulated fried egg is exposed to excessive temperatureand/or cooking time.

During and/or immediately following preheating, the mixed liquid eggwhites are preferably pumped and/or passed through the depositor for thedelivery of a specific weight or volume of mixed liquid egg whites intoa mold at a set rate. The speed or rate of the depositor may be adjusteddependent upon the temperature of the oven and cooking time exposed tothe formulated fried egg. The speed of the depositor is the rate atwhich a mold is filled with mixed liquid egg white for movement throughan oven. The molds filled with the liquid egg whites may then be passedthrough a second depositor which contains the preheated liquid eggyolks. The second depositor then deposits a desired volume of preheatedliquid egg yolk material upon the previously dispensed egg whites. Theplacement of the egg yolk material onto the egg whites is notstandardized or uniform which therefore enhances the natural appearancefor the formulated fried egg product. Following the deposit of thepreheated liquid egg yolk material into the previously partially filledmold containing the egg whites, the mold may be transported to an ovenfor cooking.

During formation of the formulated fried egg following preheating of theegg white portion, deposit of the egg white portion within the mold,and/or the initiation of the cooking of the egg white portion, theliquid egg yolk portion is heated to a temperature just below thecoagulation point for the liquid egg yolk. The heated egg yolk is thendeposited into the mold upon the preheated egg white portion. Theposition of the egg yolk portion upon the egg white portion is generallynot symmetrical and/or uniform between individual portions of theformulated fried egg. The mold containing the egg yolk and egg whiteportions is then cooked increasing the viscosity of the egg white andegg yolk portions.

A conveyor and/or an extractor device preferably inserts an empty moldand retrieves a filled mold from the Koppens dispenser. The conveyorpreferably transports molds filled with liquid egg white material to asecond depositor or dispensing machine for receipt of a portion ofliquid egg yolk material. The conveyor continues to transport the moldscontaining the liquid egg white and liquid yolk material into aconvection oven for heating.

The conveyor also preferably transports individual cooked formulatedfried eggs to a freezing and package stage where one or more of theindividual formulated fried eggs may be packaged together.

The humidity of the oven is an important factor during cooking of theformulated fried egg. Increased humidity within the oven enhances thesensory perceptions such as appearance, taste, and mouth feel for thecooked formulated fried egg. Cooking of the formulated fried egg producttherefore occurs at a high moisture atmosphere at an approximatetemperature of 350° F. or 176.67° C. A gas fired steam injection cookeras available from Hobart is adequate for the cooking purposes. Inaddition, in order to obtain a desired high moisture atmosphere, theexhaust dampers for the oven may be required to be closed. Closing ofthe oven dampers may necessarily increase the temperature within theovens by approximately 25° F. or 3.89° C. or more. It is anticipatedthat the minimum temperature of the oven is required to exceed 165° F.or 73.89° C. The oven is preferably completely preheated in order toattempt to obtain an equalibration of the cooking components.

The conditions of the oven during the initial cooking of the formulatedfried egg, and the condition of the oven during reheating of theformulated fried egg following freezing, has a large impact upon skinformation and egg texture. To minimize undesirable skin formation and tomaximize the texture, taste, mouth feel, and other sensory perceptions,the formulated fried egg should be cooked slowly at relatively lowtemperatures. In addition, humidity with the oven should be maximized.The speed of cooking of the formulated fried egg significantly impactsthe final textural properties as perceived by consumers. Cooking of theformulated fried egg to rapidly and at an increased temperature causesair bubbles to form which interrupt the egg structure and particularlythe egg white structure destroying the smooth cohesive texture for theformulated fried egg.

The oven conditions during cooking may vary. Generally, cooking of theformulated fried egg at may occur a temperature of 325° F. or 162.78° C.at a full steam setting where the cooking time is 7.75 minutes. Thesecooking conditions provide an acceptable cooked formulated fried egg.

Alternatively, cooking of the formulated fried egg may occur at atemperature of 375° F. or 190.56° C. at full steam for 6.5 minutes toyield an acceptable cooked formulated fried egg.

In another embodiment, cooking of the formulated fried egg may occur ata temperature of approximately 375° F. or 190.56° C. for 6.5 minuteswhere full steam is provided for the final one-third of the cooking timeto yield an acceptable cooked formulated fried egg.

In yet another embodiment, cooking of the formulated fried egg may occurat a temperature of approximately 425° F. or 218.33° C. for 5.5 minuteswhere full steam is provided during the entire cooking duration to yieldan acceptable cooked formulated fried egg.

A proctor oven may be utilized to cook for the formulated fried egg.Alternatively, a batch oven may be utilized to cook the formulated friedegg. The cooking times for the formulated fried egg are normally between6.5 and 8 minutes. In addition, it is preferable to lower the cookingtemperature and to increase the pH within the formulated fried egg tomaximize quality. A cooking time of 6.5 to 8 minutes has been found tobe adequate for coagulation of the egg proteins for the formulated friedegg.

In order to minimize skin formation during cooking molds containingindividual egg receiving areas are used. The molds containing theformulated egg prior to and during cooking are not required to betreated with oil and/or water. When no treatment is applied to the moldsduring cooking at relatively high temperatures, the firmness of the toplayer of the egg is reduced. In addition, the cooking of the formulatedfried egg without the use of oil, water, and/or other treatment mayresult in the undesirable dehydration and crusting of the egg surfaceand particularly the egg white surface.

During cooking of the formulated fried egg within the molds, edible oilmay be sprayed upon the top surface of the egg to deter dehydration andcrusting of the egg surface. The effectiveness of the sprayed oil uponthe surface of the egg is improved when the formulated fried egg iscooked at lower temperatures of approximately 325° F. or 162.78° C.

Alternatively, water may be sprayed upon the top surface of theformulated fried egg as within the molds during cooking to deterdehydration and crusting of the egg surface. The use of water as sprayedupon the surface of the formulated fried egg yields the shiniest andmost natural appearing fried egg.

In general, a continuous forced draft convection heating oven isutilized for cooking of the formulated fried egg. A suitable forceddraft convection heating oven is preferably identified as a WolverineProctor Convection Oven. The operational oven temperature parameters areusually identified as 325° F. to 475° F. or 162.78° C. to 246.11° C.where the dampers and relative humidity within the convection oven maybe adjusted dependent upon the local environmental conditions asidentified within the examples indicated herein.

During cooking, each mold may be covered with foil to minimizedehydration and crusting of the fried egg surface. Cooking of theformulated fried eggs within the molds as covered by aluminum foilusually occurs at lower cooking temperatures of approximately 325° F. or162.78° C. Prior to cooking of the molds as covered with aluminum foiland/or plastic material, water may be added to each egg receiving areato minimize dehydration and/or crusting of the surface of the formulatedfried egg during cooking. The inclusion of water within the eggreceiving area of the molds prior to covering with foil and/or plasticimproves the humidity of the formulated fried egg during cooking therebyreducing undesirable skin formation, dehydration, and/or crusting of thesurface of the fried egg.

The molds utilized to cook the formulated fried egg may identified asproctor oven molds where each egg receiving area has a diameter ofbetween 3 in. to 3.5 in. or 7.62 cm. to 8.89 cm. Each mold may includeone row of 3 egg receiving areas. Alternatively, a mold may include anydesired number of rows of egg receiving areas. In addition, the interiorof the egg receiving areas of each mold may be treated with siliconand/or Teflon® to reduce the undesirable sticking of the cookedformulated fried egg within the mold. Each egg receiving area of eachmold is preferably constructed and arranged to hold between 14-8 gramsof egg yolk material as deposited on 18-24 grams of egg white material.

A mold 10 having individual food receiving openings 12 may be insertedproximate to the dispensing device 26 where each individual food opening12 receives approximately 3 ounces or 86.05 grams of consumable foodproduct.

The mold as utilized herein is preferably substantially circular inshape and has a sufficient depth to hold for cooking the mixed liquidegg whites and subsequent deposited mixed liquid egg yolk material.

Referring to FIG. 1, the mold may be formed of metal, Teflon®, and/orany other desired material for use in the processing, cooling, and/orfreezing, of the formulated fried egg. The material selected for themold 10, is required to be amenable to repeated cleansing to minimizefood related health issues and/or contamination. Each individual mold isgenerally adapted to receive 3 ounces or 85.05 grams of mixed liquid eggwhite material and 3 ounces or 85.05 grams of mixed liquid egg yolkmaterial for cooking into the formulated fried egg product.

Following cooking, the molds containing the cooked formulated fried eggsmay be removed from the oven and permitted to cool at room temperaturefor approximately 30 minutes. A cross cup conveyor may then be used totransfer the molds to a freezing unit to implement freezing of the moldscontaining the formulated fried eggs.

The molds containing the cooked formulated fried eggs may be frozen inany manner as desired including, but not necessarily limited to,freezing upon exposure to carbon dioxide snow; cryogenic freezingthrough the use of liquid nitrogen within a Spyro freezer; and/orfreezing through convention freezing techniques. If a cryogenic freezingtechnique is utilized then the Spyro freezer and associated conveyor maybe set to freeze approximately 3800 units of formulated fried egg perhour. Freezing of the cooked molds holding the cooked formulated friedeggs may also occur through the use of a carbon dioxide freezing tunnelhaving a centrally disposed conveyor for transportation of the cookedmolds of formulated fried eggs. Alternatively, liquid nitrogen may beused as the freezing medium which may be either sprayed upon or exposedto the molds through conventional processing techniques. The use ofliquid nitrogen is anticipated to be sufficient to freeze 3000 lbs. ofcooked formulated fried eggs per hour.

Following cooking, the formulated fried eggs may be individually quickfrozen. Individual quick freezing of the eggs should occur in a shortduration of time. Generally as the time required for freezingingredients decreases the quality of the frozen article after thawingincreases. A Spyro freezer may be utilized to individually quick freezethe formulated fried egg product. The through-put for the freezer mayestablish a freezing time of approximately 30 minutes. The formulatedfried egg product may be exposed to a temperature below −10° F., −23.33°C. and not to exceed 20° F., −6.67° C. Individual quick freezing of thecooked formulated fried egg product provides safety advantagesminimizing food related health and/or contamination issues. Followingthe individual quick freezing of the cooked formulated fried eggproduct, the fried eggs may endure being frozen, refrigerated, and/orbeing kept hot following reheating for extended durations of timewithout the sacrifice of product quality.

The frozen formulated fried eggs may then be separated from the molds byconventional separation techniques which may include the use of vacuumassisted separation devices. Following separation from the molds, thefrozen formulated fried eggs may be individually packaged and/orpackaged in bulk for storage. The frozen formulated fried eggs mayadditionally be vacuum packaged and/or gaseous nitrogen may be utilizedto flush air from the packages to minimize risk of contamination and/orfreezer or thaw damage to the formulated fried eggs during storage.

Alternatively, the food separation device may include grasping armsand/or positioners to facilitate the separation of the cooked and frozenformulated fried egg from the interior of the respective mold. The foodseparation device may also include pneumatic and/or hydraulic pumpshaving hose conduits which in turn may be in communication with one ormore individual suction extractors. One or more valves may be utilizedto regulate the pneumatic and/or hydraulic pressure on the individualsuction devices for use in separation of the frozen formulated fried eggfrom an individual mold. The pumps and valves may regulate the pressureto be exposed to the individual extraction devices to downwardly forcethe individual extraction devices into the respective mold forseparation of the frozen formulated fried egg product from the mold.

A conveyor may be placed below the food separation device. The conveyoris preferably adapted to receive, carry, and/or transport frozenformulated fried eggs following separation from an individual mold forpackaging.

Prior to reheating of the frozen formulated fried eggs, thawing isgenerally required. Following the thawing of the previously frozenformulated fried eggs, the eggs may be reheated within a conventionaloven or microwave oven prior to consumption by an individual. The thawedformulated fried eggs are generally required to be covered or enclosedwithin a medium such as plastic to minimize dehydration, the formationof undesirable skin, and/or crusting of the surface of the fried eggduring reheating. In addition, the power setting for a microwave ovenshould be reduced to minimize undesirable skin formation. Reheatingthrough the use of a conventional oven generally also requires that theformulated fried eggs be covered to minimize undesirable skin formation,dehydration, and/or crusting of the surface of the eggs. Alternatively,humidity may be increased within the oven as earlier described tomaximize the quality of the reheated formulated fried eggs.Alternatively, steam injection cooking may be utilized to reheat athawed formulated fried egg which may eliminate the necessity forcovering of the eggs or cooking wells containing the thawed formulatedfried eggs during reheating.

Various ingredients are utilized to provide a desired quality for acomposite formulated fried egg. Generally, the ingredients to beincorporated into the formulated fried egg include: egg yolk; xanthangum; salt; corn syrup solids; citric acid; carrageenan; annatto; wholeegg; hard cooked yolk; water; propylene glycol; egg whites; soy beanoil; modified food starch; ProMix (non-fat dry milk and whey solids);polar gel modified food starch; SLS; delight modified food starch; guargum; white pepper; and natural egg flavor. Further, the formulated friedegg product may include water, soy bean oil, corn oil, citric acid,and/or butter flavor. The ingredients described herein have beenprovided for illustrative purposes only and the group of ingredientsidentified herein may comprise any number of additional items identifiedin this description or which have not been previously identified.

Egg whites generally comprise between 50% and 99.5% of the total percentweight of the entire egg white portion of the formulated fried eggproduct. Water is generally provided in an amount between 0% and 10% ofthe total weight of the egg white portion. Soy bean oil and/or corn oilis usually provided between 0% and 10% as based upon the percentage oftotal weight for the egg white portion. Modified food starch isgenerally provided between 0% to 3% of the total weight of the egg whiteportion. ProMix or non-fat dried milk and whey solids generally providebetween 0% to 3% of the total weight of the egg white portion. Salt isgenerally provided between 0% to 1% of the total weight of the egg whiteportion. Xanthan gum is generally provided between 0% to 0.4% of thetotal weight of the egg white portion. Polar gel is generally providedbetween 0% to 3% of the total weight of the egg white portion. Citricacid is generally provided between 0% to 0.2% of the total weight of theegg white portion. SLS is generally provided between 0% to 0.4% of thetotal weight of the egg white portion. Delight modified food starch isgenerally provided between 0% to 2.5% of the total weight of the eggwhite portion. Guar gum generally forms between 0% to 0.3% of the totalweight of the egg white portion. Propylene glycol is generally providedbetween 0% and 0.3% of the total weight of the egg white portion. Whitepepper generally forms between 0% to 0.05% of the total weight of theegg white portion. Natural egg flavor also generally provides between 0%and 0.1% of the total weight of the egg white portion.

The egg yolk portion generally has egg yolks in the percentage amountbetween 50% to 99.9% of the total weight of the egg yolk portion of theformulated fried egg product. Xanthan gum is generally provided between0% to 0.5% of the total weight of the egg yolk portion. Salt isgenerally provided between 0% to 0.4% of the total weight of the eggyolk portion. Citric acid is generally provided between 0% to 0.15% ofthe total weight of the egg yolk portion. Carrageenan generally formsbetween 0% to 0.3% of the total weight of the egg yolk portion. Wholeegg is generally provided between 0% to 0.50% of the total weight of theegg yolk portion. Hard cooked egg yolk is generally provided between 0%to 0.45% of the total weight of the egg yolk portion. Water is generallyprovided between 0% to 15% of the total weight of the egg yolk portion.Propylene glycol is generally provided between 0% to 0.1% of the totalweight of the egg yolk portion and egg whites are generally providedbetween 0% to 20% of the total weight of the egg yolk portion.

A typical formula for the egg white portion utilized within theformulated fried egg product would involve the use of egg whitesconstituting 81% of the total weight of the egg white portion of thefried egg product; water comprising 10% of the total weight of the eggwhite portion of the fried egg product; soy bean oil/corn oilconstituting 4% of the total weight of the egg white portion of thefried egg product; modified food starch being 2.5% of the total weightof the egg white portion of the fried egg product; ProMix 632 (non-fatdry milk and whey solids) where the ProMix 632 constitutes 2% of thetotal weight of the egg white portion of the fried egg product; salt inthe a amount 0.35% of the total weight of the egg white portion of thefried egg product; and xanthan gum in the amount of 0.15% of the totalweight of egg white portion of the fried egg product.

An alternative formula the egg white portion would include egg whitesbeing 85.9% of the total weight of the egg white portion of the friedegg product; water being 7.15% of the total weight of the egg whiteportion of the fried egg product; soy bean oil being 4% of the totalweight of the egg white portion of the fried egg product; modified foodstarch being 2.5% of the total weight of the egg white portion of thefried egg product; salt being 0.35% of the total weight of the egg whiteportion of the fried egg product; citric acid being 0.1% of the totalweight of the egg white portion of the fried egg product.

Another alternative formula the egg white portion would include eggwhites in the amount of 93.15% of the total weight of the egg whiteportion of the fried egg product; soy bean oil in the amount of 4% ofthe total weight of the egg white portion of the fried egg product;modified food starch in the amount of 2.5% of the total weight of theegg white portion of the fried egg product; and salt in the amount of0.35% of the total weight of the egg white portion of the fried eggproduct.

In still another formula the egg white portion would include the use ofegg whites in the amount of 97.15% of the total weight of the egg whiteportion of the fried egg product; modified food starch in the amount of2.5% of the total weight of the egg white portion of the fried eggproduct; and salt in the amount of 0.35% of the total weight of the eggwhite portion of the formulated fried egg product.

In another alternative formula the egg white portion would include theuse of the egg white which would constitute 86% of the total weight ofthe egg white portion of the formulated fried egg product; water wouldbe 7.15% of the total weight of the egg white portion of the formulatedfried egg product; soy bean oil would form 4% of the total weight of theegg white portion of the formulated fried egg product; modified foodstarch would form 2.5% of the total weight of the egg white portion ofthe formulated fried egg product; and salt would be 0.35% of the totalweight of the egg white portion of the formulated fried egg product.

In another alternative formula the egg white portion would include theegg whites forming 93.15% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 4% ofthe total weight of the egg white portion of the formulated fried eggproduct; modified food starch would constitute 2.5% of the total weightof the egg white portion of the formulated fried egg product; and saltwould constitute 0.35% of the total weight of the egg white portion ofthe formulated fried egg product.

In an alternative formula the egg white portion would include egg whitesforming 91.65% of the total weight of the egg white portion of theformulated fried egg product; soy bean oil would constitute 6% of thetotal weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 2% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.35% of the total weight of the egg white portion of the formulatedfried egg product; and xanthan gum would constitute 0.3% of the totalweight of the egg white portion of the formulated fried egg product.

In another alternative formula the egg white portion would include eggwhites forming 83% of the total weight of the egg white portion of theformulated fried egg product; water would constitute 10% of the totalweight of the egg white portion of the fried egg product; soy bean oilwould constitute 4% of the total weight of the egg white portion of theformulated fried egg product; modified food starch would constitute 2.5%of the total weight of the egg white portion of the formulated fried eggproduct; xanthan gum would constitute 0.15% of the total weight of theegg white portion of the formulated fried egg product; and salt wouldconstitute 0.35% of the total weight of the egg white portion for theformulated fried egg product.

In another alternative formula the egg white portion would include eggwhites forming 85.65% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 5% ofthe total weight of the egg white portion of the formulated fried eggproduct; water would constitute 7% of the total weight of the egg whiteportion of the formulated fried egg product; modified food starch wouldconstitute 2% of the total weight of the egg white portion of theformulated fried egg product; and salt would constitute 0.35% of thetotal weight of the egg white portion of the formulated fried eggproduct.

In yet another formula the egg white portion would include egg whitesforming 86% of the total weight of the egg white portion of theformulated fried egg product; water would constitute 7.15% of the totalweight of the egg white portion of the formulated fried egg product; soybean oil would constitute 4% of the total weight of the egg whiteportion of the formulated fried egg product; modified food starch wouldconstitute 2.5% of the egg white portion of the formulated fried eggproduct; and salt would constitute 0.35% of the egg white portion of theformulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 89.1% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 8% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 2.5% of the total weight of the eggwhite portion of the formulated fried egg product; and salt wouldconstitute 0.4% of the total weight of the egg white portion of theformulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 91.1% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 6% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 2.5% of the total weight of the eggwhite portion of the formulated fried egg product; and salt wouldconstitute 0.4% of the total weight of the egg white portion of theformulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 92.45% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 6% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and xanthan gum would constitute 0.15% of the totalweight of the egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 99.25% of the total weight of the egg white portionof the formulated fried egg product; polar gel would constitute 0.5% ofthe total weight of the egg white portion of the formulated fried eggproduct; and xanthan gum would constitute 0.25% of the total weight ofthe egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 98.88% of the total weight of the egg white portionof the formulated fried egg product; polar gel would constitute 1% ofthe total weight of the egg white portion of the formulated fried eggproduct; and xanthan gum would constitute 0.13% of the total weight ofthe egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 87.1% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 10% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 2.5% of the total weight of the eggwhite portion of the formulated fried egg product; and salt wouldconstitute 0.4% of the total weight of the egg white portion of theformulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 90.55% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 8% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and xanthan gum would constitute 0.05% of the totalweight of the egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 89.1% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 9% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1.5% of the total weight of the eggwhite portion of the formulated fried egg product; and salt wouldconstitute 0.4% of the total weight of the egg white portion for theformulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 90.05% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 8% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1.5% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and xanthan gum would constitute 0.05% of the totalweight of the egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 91.6% of the total weight of the egg white portion ofthe formulated fried egg product; soy bean oil would constitute 8% ofthe total weight of the egg white portion of the formulated fried eggproduct; and salt would constitute 0.4% of the total weight of the eggwhite portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 99% of the total weight of the egg white portion ofthe formulated fried egg product; and SDS would constitute 1% of thetotal weight of the egg white portion of the formulated fried eggproduct.

In yet another alternative formula the egg white portion would includeegg whites forming 99.5% of the total weight of the egg white portion ofthe formulated fried egg product; and SDS would constitute 0.5% of thetotal weight of the egg white portion of the formulated fried eggproduct.

In yet another alternative formula the egg white portion would includeegg whites forming 99.9% of the total weight of the egg white portion ofthe formulated fried egg product; and SDS would constitute 0.1% of thetotal weight of the egg white portion of the formulated fried eggproduct.

In yet another alternative formula the egg white portion would includeegg whites forming 94.25% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 4% ofthe total weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1.25% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and SLS would constitute 0.1% of the total weight ofegg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 94.25% of the total weight of the egg white portionof the formulated fried egg product; soy bean oil would constitute 2% ofthe total weight of the egg white portion of the formulated fried eggproduct; delight modified food starch would constitute 2% of the totalweight of the egg white portion of the formulated fried egg product;polar gel would constitute 1.25% of the total weight of the egg whiteportion of the formulated fried egg product; salt would constitute 0.4%of the total weight of the egg white portion of the formulated fried eggproduct; and SLS would constitute 0.1% of the total weight of the eggwhite portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 93% of the total weight of the egg white portion ofthe formulated fried egg product; delight modified food starch wouldconstitute 2% of the total weight of the egg white portion of theformulated fried egg product; soy bean oil would constitute 2% of thetotal weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 2.5% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and SLS would constitute 0.1% of the total weight ofthe egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 94% of the total weight of the egg white portion ofthe formulated fried egg product; delight modified food starch wouldconstitute 2% of the total weight of the egg white portion of theformulated fried egg product; soy bean oil would constitute 2% of thetotal weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1.25% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and SLS would constitute 0.35% of the total weight ofthe egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 95.5% of the total weight of the egg white portion ofthe formulated fried egg product; delight modified food starch wouldconstitute 2% of the total weight of the egg white portion of theformulated fried egg product; soy bean oil would constitute 2% of thetotal weight of the egg white portion of the formulated fried eggproduct; salt would constitute 0.4% of the total weight of the egg whiteportion of the formulated fried egg product; and SLS would constitute0.1% of the total weight of the egg white portion of the formulatedfried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 94.25% of the total weight of the egg white portionof the formulated fried egg product; water would constitute 4% of thetotal weight of the egg white portion of the formulated fried eggproduct; polar gel would constitute 1.25% of the total weight of the eggwhite portion of the formulated fried egg product; salt would constitute0.4% of the total weight of the egg white portion of the formulatedfried egg product; and SLS would constitute 0.1% of the total weight ofthe egg white portion of the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 97.2% of the total weight of the egg white portion ofthe formulated fried egg product; polar gel would constitute 2.5% of thetotal weight of the egg white portion of the formulated fried eggproduct; xanthan gum would constitute 0.2% of the total weight of theegg white portion of the formulated fried egg product; and citric acidwould constitute 0.1% of the total weight of the egg white portion ofthe formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 93.84% of the total weight of the egg white portionof the formulated fried egg product; water would constitute 3% of thetotal weight of the egg white portion of the formulated fried eggproduct; Purity starch would constitute 2% of the total weight of theegg white portion of the formulated fried egg product; salt wouldconstitute 0.8% of the total weight of the egg white portion of theformulated fried egg product; propylene glycol would constitute 0.2% ofthe total weight of the egg white portion of the formulated fried eggproduct; xanthan gum would constitute 0.1% of the total weight of theegg white portion of the formulated fried egg product; white pepperwould constitute 0.04% of the total weight of the egg white portion ofthe formulated fried egg product; and citric acid would constitute 0.02%of the total weight of the egg white portion of the formulated fried eggproduct. In yet another alternative formula the egg white portion wouldinclude egg whites forming 97.2% of the total weight of the egg whiteportion of the formulated fried egg product; polar gel would constitute2.5% of the total weight of the egg white portion of the formulatedfried egg product; xanthan gum would constitute 0.2% of the total weightof the egg white portion of the formulated fried egg product; and citricacid would constitute 0.1% of the total weight of the egg white portionof the formulated fried egg product.

In yet another alternative formula the egg white portion would includeegg whites forming 85.6% of the total weight of the egg white portion ofthe formulated fried egg product; water would constitute 10% of thetotal weight of the egg white portion of the formulated fried eggproduct; non-fat dry milk would constitute 1% of the total weight of theegg white portion of the formulated fried egg product; purity W modifiedfood starch would constitute 2% of the total weight of the egg whiteportion of the formulated fried egg product; salt would constitute 0.4%of the total weight of the egg white portion of the formulated fried eggproduct; and natural flavor for fried egg would constitute 1% of thetotal weight of the egg white portion of the formulated fried eggproduct.

A formula for the egg yolk portion of the formulated fried egg productwould constitute egg yolks forming 99.57% of the total weight of the eggyolk portion of the formulated fried egg product; xanthan gum would form0.225% of the total weight of the egg yolk portion of the formulatedfried egg product; and salt would constitute 0.4% of the total weight ofthe egg yolk portion of the formulated fried egg product.

In yet another formula for the egg yolk portion of the formulated friedegg product would constitute egg yolks forming 50% of the total weightof the egg yolk portion of the formulated fried egg product; whole eggwould constitute 49.55% of the total weight of the egg yolk portion ofthe formulated fried egg product; and xanthan gum would form 0.45% ofthe total weight of the egg yolk portion of the formulated fried eggproduct.

In yet another formula for the egg yolk portion of the formulated friedegg product would constitute egg yolks forming 50.05% of the totalweight of the egg yolk portion of the formulated fried egg product; hardcooked yolk would constitute 39.83% of the total weight of the egg yolkportion of the formulated fried egg product; water would constitute 10%of the total weight of the egg yolk portion of the formulated fried eggproduct; xanthan gum would constitute 0.05% of the total weight of theegg yolk portion of the formulated fried egg product; propylene glycolwould constitute 0.05% of the total weight of the egg yolk portion ofthe formulated fried egg product; and citric acid would constitute 0.02%of the egg yolk portion of the formulated fried egg product.

In yet another formula for the egg yolk portion of the formulated friedegg product would constitute egg yolks forming 79.9% of the total weightof the egg yolk portion of the formulated fried egg product; egg whiteswould constitute 19.5% of the total weight of the egg yolk portion ofthe formulated fried egg product; xanthan gum would constitute 0.25% ofthe total weight of the egg yolk portion of the formulated fried eggproduct; carrageenan would constitute 0.25% of the total weight of theegg yolk portion of the formulated fried egg product; and citric acidwould constitute 0.1% of the total weight of the egg yolk portion of theformulated fried egg product.

The procedures identified herein enable individual formulated fried eggsto be held frozen, refrigerated and/or hot for extended periods of timewithout loss of product integrity.

The temperature of the formulated fried egg within the mold 10 followingfreezing is verified to not exceed 36° F. or 2.22° C. The frozenformulated fried eggs may then be packaged in poly lined bags and storedin a freezer for future transportation, delivery, reheating, andconsumption by an individual.

EXAMPLES Example I

Initially, shell eggs were broken and separated into liquid egg yolkportions and liquid egg white portions by commercial egg shelling andseparation techniques. 600.6 grams of liquid egg yolk were placed into amixing vessel. Next, 120 ml. of cold water was combined with 477.96grams of hard cooked egg yolk in a mixer whereupon mixing occurred.Next, 0.6 grams of propylene glycol were combined to 0.6 grams ofxanthan gum in a bucket where mixing occurred through use of a whisk.Next, 0.24 grams of citric acid were added to the glycol/gum mixturewhereupon mixing occurred. The mixed glycol/gum/citric acid mixture andwater/hard cooked egg yolk mixture were added to the liquid egg yolkwhere agitation occurred. The mixed yolk portion was then transferred toa heat exchanger for preheating to a temperature just below the yolkcoagulation point. The preheated liquid egg yolk portion was then pumpedto a yolk depositor.

3,753.6 grams of egg whites were added to a mixing vessel. Next, 120 ml.of hot water were combined with 80 grams of modified food starch wheremixing occurred. Next, 8 grams of propylene glycol and 4 grams ofxanthan gum were then added to a bucket and mixed with a whisk. Theglycol/gum mixture was then added to the water/starch mixture whereuponmixing occurred. The resulting mixture was combined with the liquid eggwhites where mixing occurred.

The liquid egg white portion was then transferred to a heat exchangerfor preheating. The preheated liquid egg white portion was then pumpedto a egg white depositor for placement within a plurality of molds. Themolds containing the preheated liquid egg white portion were thenexposed to heat of approximately 325° F. or 162.78° C. The mold was thentransferred to a yolk depositor whereupon a desired volume of preheatedegg yolk was deposited upon the heated egg white portion. The moldscontaining the egg white portion and egg yolk portion were thentransferred to a convection oven whereupon cooking occurred for 7.75minutes at a temperature of 325° F. or 162.78° C. with the humidity setat full steam with the dampers closed. Following cooking the molds weretransferred to a cooling area where the molds were permitted to cool atroom temperature for a period of 30 minutes. Next, the cooled molds offormulated fried eggs were transferred to a cryogenic Spyro freezer forquick freezing. Following freezing, the frozen formulated fried eggswere separated from the molds for packaging and storage. Next, thepackaged frozen formulated fried eggs were thawed and were reheatedwithin a microwave oven at a low power setting where the formulatedfried eggs were covered with microwave compatible plastic to preventdehydration, skin formation, and/or crusting. The formulated friedobtained according to the above-identified methodology provided asuperior formulated fried egg resembling a natural fried egg inappearance, taste, and mouth feel.

Example II

Initially, shell eggs were broken and separated into liquid egg yolkportions and liquid egg white portions by commercial egg shelling andseparation techniques. 958.8 grams of liquid egg yolk were added to amixing vessel. Next, 234 grams of egg whites were combined with 2.99grams of xanthan gum and 2.99 grams of carrageenen whereupon mixingoccurred. Next, 1.20 grams of citric acid were added to the eggwhite/gum/carrageenen mixture whereupon mixing occurred. The resultingmixture was then added to the liquid egg yolk where agitation occurred.The mixed yolk portion was then transferred to a heat exchanger forpreheating to a temperature just below the yolk coagulation point. Thepreheated liquid egg yolk portion was then pumped to a yolk depositor.

2,430 grams of liquid egg whites were added to a mixing vessel. Next,62.5 grams of polar gel were combined with 5 grams of xanthan gum and2.5 grams of citric acid whereupon mixing occurred. The mixed polargel/gum/citric acid was then added to the liquid egg yolks whereuponmixing occurred. The liquid egg white portion was then transferred to aheat exchanger for preheating. The preheated liquid egg white portionwas then pumped to a egg white depositor where placement within aplurality of molds occurred. The molds containing the preheated liquidegg white portions were then exposed to heat of approximately 375° F. or190.56° C. The molds were then transferred to a yolk depositor where adesired volume of egg yolk was deposited upon the egg white portion. Themolds containing the egg white portion and egg yolk portion were thentransferred to a convection oven where cooking occurred for 6.5 minutesat a temperature of 375° F. or 190.56° C. with the humidity set at fullsteam with the oven dampers closed. Following cooking, the molds weretransferred to a cooling area where the molds were cooled at roomtemperature for a period of 30 minutes. Next, the cooled molds offormulated fried eggs were transferred to a cryogenic Spyro freezer forquick freezing. Following freezing, the formulated fried eggs wereseparated from the molds for packaging and storage. Next, the packagefor frozen formulated fried eggs were thawed and were reheated within amicrowave oven at a low power setting where the formulated fried eggswere covered with microwave compatible plastic to prevent dehydration,skin formation, and/or crusting. The formulated fried eggs obtainedaccording to the above-identified methodology provided a superiorformulated fried egg resembling a natural fried egg in appearance,taste, and mouth feel.

Example III

Initially, shell eggs were broken and separated into liquid egg yolkportions and liquid egg white portions by commercial egg shelling andseparation techniques. 500 grams of liquid egg yolk were added to amixing vessel. Next, 495.5 grams of whole egg and 4.5 grams of xanthangum were placed in a mixing vessel and mixed. The mixed whole egg andgum were then added to the liquid egg yolk whereupon mixing occurred.The mixed yolk portion was then transferred to a heat exchanger forpreheating to a temperature just below the yolk coagulation point. Thepreheated liquid egg yolk portion was then pumped to a yolk depositor.

890.5 grams of liquid egg whites were added to a mixing vessel. Next, 80grams of soy bean oil, 25 grams of polar gel, 5 grams of salt, and 0.5grams of xanthan were added to a mixing vessel and mixed. The mixedoil/gel/salt/gum was then added to the liquid egg whites where mixingoccurred. The liquid egg white portion was then transferred to a heatexchanger for preheating. The preheated liquid egg white portion wasthen pumped to an egg white depositor where placement within a pluralityof molds occurred. The molds containing the preheated liquid egg whiteportions were then exposed to heat of approximately 375° F. or 190.56°C. The molds were then transferred to a yolk depositor where a desiredvolume of egg yolk was placed upon the egg white portion within themold. The molds containing the egg white portion and egg yolk portionwere then transferred to a convection oven where cooking occurred for6.5 minutes at a temperature of approximately 375° F. or 190.56° C.where full steam was provided for the final one-third of the cookingtime. The oven dampers closed during the final one-third of the cookingtime to maximize humidity. Following cooking, the molds containing thecooked formulated fried eggs were transferred to a cooling area wherethe molds were cooled at room temperature for a period of 30 minutes.Next, the cooled molds of formulated fried eggs were transferred to acryogenic Sypro freezer for quick freezing. Following freezing, thefrozen formulated fried eggs were separated from the molds for packagingand storage. Next, the packaged frozen formulated fried eggs were thawedand were reheated within a microwave oven at a low power setting wherethe formulated fried eggs were covered with microwave compatible plasticto prevent dehydration, skin formation, and/or crusting. The formulatedfried eggs obtained according to the above-identified methodologyprovided a superior formulated fried egg resembling a natural fried eggin appearance, taste, and mouth feel.

The above-identified ingredients, temperature, and processing proceduresresulted in a formulated fried egg having increased thickness, improvedcolor, texture, mouth feel, and the over all appearance of a naturallyfried egg.

It should be noted that the process steps identified above may besubstantially interchained and modified without sacrifice as to thefinal formulated fried egg so long as temperature is regulated andmixing time is regulated to avoid excessive temperatures and overmixing.

In general, the ingredients identified herein have been provided forillustrative purposes and should not be considered as restrictive. Inaddition, reference herein to modified food starch may generally includea wide variety of commercially available corn starches and/or potatostarches used in food products which are FDA approved for consumption byindividuals. In addition, certain sugars may be used as substitutes foror in combination with either of the modified food starches identifiedherein. Further, reference herein to soy oil and/or corn oil may includereference to other edible oils namely peanut oil, and vegetable oils. Itshould also be noted that a number of alternative edible oils mayadequately function as substitute ingredients for the identified soybean oil and/or corn oil herein.

Carboxymethylcellulose, carrageenan, guar gums, locust bean gum, betacarotene, agar, glycerol mono stearate, mono diglycerides andpolypropylene glycol esters may function as acceptable substitutesand/or replacements for the xanthan gum and the gums and emulsifiersherein. Further, other milk products may be substituted for the non-fatdry milk and whey as used herein for incorporation into the consumablefood product including eggs.

It should be noted that the percentage weights provided herein have beenrounded mathematically which in certain instances may not exactly equal100%. In these instances, the percentage of eggs and/or water may beinsignificantly increased or decreased to provide a 100% summation.

The above examples and disclosure are intended to be illustrative andnot exhaustive. These examples and description will suggest manyvariations and alternatives to one of ordinary skill in the art. All ofthese alternatives and variations are intended to be included within thescope of the attached claims. Those familiar with the art may recognizeother equivalents to the specific embodiments described herein whichequivalents are also intended to be encompassed by the claims attachedhereto.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof, therefore,the illustrative embodiments should be considered in all respects asillustrative and not restrictive, reference being made to dependentclaims rather than to the foregoing description to indicate the scope ofthe invention.

While this invention may be embodied in many different forms, there aredescribed in detail herein specific preferred embodiments of theinvention. This description is an exemplification of the principles ofthe invention and is not intended to limit the invention to theparticular embodiments illustrated.

For the purposes of this disclosure, like reference numerals in thefigures shall refer to like features unless otherwise indicated.

Further, the particular features presented in the dependent claims canbe combined with each other in other manners within the scope of theinvention such that the invention should be recognized as alsospecifically directed to other embodiments having any other possiblecombination of the features of the dependent claims. For instance, forpurposes of claim publication, any dependent claim which follows shouldbe taken as alternatively written in a multiple dependent form from allprior claims which possess all antecedents referenced in such dependentclaim if such multiple dependent format is an accepted format within thejurisdiction (e.g. each claim depending directly from claim 1 should bealternatively taken as depending from all previous claims). Injurisdictions where multiple dependent claim formats are restricted, thefollowing dependent claims should each be also taken as alternativelywritten in each singly dependent claim format which creates a dependencyfrom a prior antecedent-possessing claim other than the specific claimlisted in such dependent claim below (e.g. claim 3 may be taken asalternatively dependent from claim 2; claim 4 may be taken asalternatively dependent on claim 2, or on claim 3; claim 6 may be takenas alternatively dependent from claim 5; etc.).

This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

1. A process for making a formulated fried egg, the process comprising:a) forming an egg white portion comprising egg whites which form between81% and 99% by weight of the egg white portion, oil which forms between2% and 10% by weight of the egg white portion, and salt which formsbetween 0.35% and 0.8% by weight of the egg white portion; b) forming anegg yolk portion comprising egg yolk, which forms between 50% and 99.9%by weight of the egg yolk portion and gum, which forms between 0.1% and0.5% by weight of the egg yolk portion; c) preheating the egg whiteportion separately from the egg yolk portion; d) depositing a desiredamount of the egg white portion into a mold; e) depositing a desiredamount of the egg yolk portion into the mold; f) cooking the desired eggyolk amount and desired egg white amount in the mold; g) removing thecooked egg yolk portion and egg white portion from the mold; and h)cooling the cooked and removed egg yolk portion and egg white portion.2. The process of claim 1, wherein depositing the egg yolk portion isperformed after depositing the egg white portion.
 3. The process ofclaim 1, in which the egg yolk portion and egg white portion depositingis performed using a depositor and in which the mold is positionedbeneath the depositor prior to the egg yolk portion and the egg whiteportion being deposited.
 4. The process of claim 1, further comprisingpre-heating the egg yolk portion prior to depositing the egg yolkportion.
 5. The process of claim 1, the egg white portion furthercomprising modified food starch, the modified food starch formingbetween 1% and 3% by weight of the egg white portion.
 6. The process ofclaim 5, the egg yolk portion further comprising citric acid, the citricacid forming between 0.01% and 0.2% by weight of the egg yolk portion.7. The process of claim 6, in which the egg white portion formsapproximately 50% by weight of the formulated fried egg.
 8. The processof claim 6, in which the egg white portion further comprises gum, thegum forming between 0.01% and 0.4% by weight of the egg white portion.9. The process of claim 6, in which the egg yolk portion furthercomprises salt, the salt forming between 0.01% and 0.5% by weight of theegg yolk portion.
 10. The process of claim 1, further comprisingdegassing the egg white portion sometime prior to the depositing of theegg white portion.
 11. The process of claim 10, in which the degassingincludes subjecting the egg white portion to a vacuum.